Method and apparatus for controlled production of a gas

ABSTRACT

An apparatus is provided to generate a gas by mixing chemicals with water. Typically, the production of gas, particularly oxygen, by combining water with powders and other dry chemicals has not been widely employed. There have existed a number of preexisting barriers such as undesirable flow rates and yields. However, by utilizing multiple reaction chambers the flow rates and yields can be more precisely tailored for a variety of situations that may call for particular flow rates and yields. Additionally, the use of the dry chemicals would allow for a long self-life allowing the apparatus to be particularly useful in emergency situations.

CROSS-REFERENCED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/045,805 entitled “METHOD AND APPARATUS FOR CONTROLLED PRODUCTION OF AGAS” (Docket No. ROSS 3050000) filed Jan. 28, 2005, which relates to andclaims priority from co-pending U.S. patent application Ser. No.10/718,131 entitled “METHOD AND APPARATUS FOR GENERATING OXYGEN” (DocketNo. ROSS 2864000), filed Nov. 20, 2003, and co-pending U.S. patentapplication Ser. No. 10/856,591, entitled “APPARATUS AND DELIVERY OFMEDICALLY PURE OXYGEN” (Docket No. ROSS 2934000), filed May 28, 2004,the contents of each of which are hereby incorporated by reference forall purposes.

FIELD OF THE INVENTION

The present invention relates generally to a gas delivery system and,more particularly, to a system that provides an activation method andapparatus as well as a method and apparatus for improving andcontrolling the gas yield, flow rates and gas production duration.

DESCRIPTION OF THE RELATED ART

Oxygen and other gas generators using chemical reactions have been knownfor some time. However, none of the conventional devices relating tochemical gas generators have resulted in variable control of the gasgeneration, while providing higher outputs of gas volume and flow rate,and simultaneously maintaining or improving control of pressure,temperature, and so forth. Gas volume and flow rate are particularlyimportant in emergency oxygen markets. For example, institutions such asthe Food & Drug Administration, the American Heart Association and theAmerican Medical Association have required or recommended, as the casemay be, a delivery of 90 liters over a 15 minute period, oralternatively an average or minimum flow rate of 6 liters per minuteover a 15 minute period. Some attempts to control the flow rate ofoxygen have included a catalyst with a gum Arabic solution. Theresultant reaction reaches a flow rate of 2 liters per minute after 30minutes. Other devices create a tablet out of an oxygen generatingagent, which similarly produces a low reaction onset (the flow rate atwhich the reaction commences) and low flow rates over the reactionperiod. These prior attempted solutions may not be suitable foremergency applications, usually medical in nature or situations wherelife-threatening factors are present where high flow rates of at least 2liters per minute to 6 liters per minute or higher are required almostinstantly.

In addition, conventional generators have had limited adoption incommerce and in industry. There are several possible factorscontributing to this lack of adoption. These factors may include one ora combination of unfavorable characteristics relating to reusability,safety, ease of use/operation, speed of use, heat management, cost,weight, aesthetic design, environmental impact, manufacturability,portability, medical efficacy, effectiveness, flow rate, gas yield,reaction stability, and purity of the gas. Some or all of thesecharacteristics are not addressed, or are inadequately addressed, by thedesigns in the prior art.

Designs in the prior art have not adequately addressed flow rate andtotal gas yield. Depending on the situation, such as for oxygenproduction in emergency situations, high flow rates may be required. Forexample, the United States Food and Drug Administration (FDA) has longrequired a flow rate performance for oxygen generators of at least 6liters per minute over 15 minutes in order to obtain market clearancefor over the counter purchase, resulting in at least a total oxygenyield requirement of 90 liters.

High pressures generated inside the reaction chamber generally accompanyhigher flow rate outputs or requirements. High pressure, such as can becreated by confined gases can be particularly dangerous.

Therefore, a need exists for a method and/or apparatus for activatinggas production and controlling gas production from a chemical reactionthat addresses at least some of the problems associated withconventional methods and apparatus for producing gases, and morespecifically medically pure oxygen.

SUMMARY OF THE INVENTION

The present invention provides an apparatus for generating gas from aplurality of separated chemicals. In one embodiment, a plurality ofreaction chambers operate cooperatively when the separated chemicals arecombined to generate the gas. The flow rate and the total yield can thenbe varied based on the proportion of separated chemicals in eachreaction chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a diagram, partly in section, depicting an exploded side viewof gas activation, production, dispensing and control vessel inaccordance with an embodiment of the present invention;

FIG. 2 is a diagram, partly in section, depicting a side view of aprimed gas activation, production, dispensing and control vessel;

FIG. 3 is a schematic sectional view of the gas activation, production,dispensing and control vessel, in use, with the spiked plungersinserted;

FIG. 4A is a plan view of an example of a screen;

FIG. 4B is a sectional view of the screen depicted in FIG. 4A;

FIG. 5A depicts a plan view of a foam breaker, taken along the lines 5B,5C;

FIG. 5B depicts a cross sectional view of the foam breaker of FIG. 5A;

FIG. 5C depicts a cross sectional view of the foam breaker of FIGS. 5Aand 5B when compressed;

FIG. 6A depicts a plan cross sectional view of a handle useful inconnection with the present invention;

FIG. 6B depicts a side cross sectional view of a handle useful inconnection with the present invention, taken along the line 6B;

FIG. 7 of the drawings is a partially cross sectioned view of a femaleconnector useful in connection with the present invention;

FIG. 8 depicts a cross sectional view of a male connector adapted to fitwith the female connector depicted in FIG. 7;

FIG. 9 depicts a side view, partly in cross section, of of oneembodiment of the connectable spiked plunger, as connected to the femaleconnector depicted in FIG. 7;

FIG. 10A depicts a side cross sectional view of a spiked plunger;

FIG. 10B depicts a side cross sectional view of a spiked plunger in itsfemale connector housing, with the spiked plunger disconnected;

FIG. 10C depicts a side cross sectional view of a spiked plunger in itsfemale connector housing, with the spiked plunger connected to it;

FIG. 11 depicts a side cross sectional view of a spring loaded spikedplunger and release mechanism;

FIG. 12 depicts a side cross sectional view of a cartridge filled withinitially separated chemicals and having a pressure relief system;

FIG. 13A depicts a side cross sectional view of an activation system forone reaction chamber of the gas activation, production, dispensing andcontrol vessel depicted in FIGS. 1 and 2, having a spike, with the spikewithdrawn for clarity;

FIG. 13B depicts a side cross sectional view of an activation system forone reaction chamber of the gas activation, production, dispensing andcontrol vessel depicted in FIGS. 1 and 2, having a spike inserted intothe container holding the water to rupture it and allow mixing the theother chemicals to create a flow of gas, with the flow of gas producedindicated by arrows;

FIG. 14 depicts a side cross sectional view of an activation system withdual reaction chambers having spikes as depicted in FIGS. 10A, 10B and10C, and having a hanging catalyst bag, with the spike withdrawn andprimed for activation;

FIG. 15 depicts a side cross sectional view of an another embodiment ofan activation system with dual reaction chambers having spikes asdepicted in FIG. 9, the male connectors depicted in FIG. 8, andcompartments for retaining the catalyst and water as depicted in FIG.16A with the spike withdrawn and primed for activation;

FIG. 16A depicts a cross-sectional side view of the water containmenthousing and an adjacent catalyst dispersal housing depicted in FIG. 15;

FIG. 16B depicts cross-sectional side view of a modified version of thecatalyst dispersal housing depicted in FIG. 16A;

FIG. 17A depicts a side cross sectional view of another embodiment of anactivation system for one reaction chamber, having a fixed activationmember, in the primed position;

FIG. 17B depicts a side cross sectional view of the embodiment of anactivation system for one reaction chamber depicted in FIG. 17A, afteractivation, the arrows indicating flow of the water and catalyst;

FIG. 18A depicts a front view, partly in phantom, of a powder releasepouch cartridge assembly;

FIG. 18B is a sectional side view of the powder release pouch cartridgeassembly depicted in FIG. 18A, taken along line 18A-A;

FIG. 19 is a partially diagrammatic side view of a bubbler;

FIG. 20 is a diagram depicting a heat exchanger/radiator;

FIG. 21 depicts a side cross sectional view of an embodiment of acartridge for one reaction chamber, showing different locations for thecatalyst and gas/oxygen producing agent;

FIG. 22 depicts a side cross sectional view of another embodiment of acartridge for one reaction chamber;

FIG. 23A depicts a cross-sectional front view of a container forcontaining pouch-type reaction chambers as depicted in FIGS. 26A and26B, utilizing a mechanical lever to initiate the gas-generatingreaction;

FIG. 23B depicts a cross-sectional side view of the container depictedin FIG. 23A, taken along the line 23A-23A.

FIG. 24A is a diagram contrasting the flow rate of two gas producingreactions;

FIG. 24B is a diagram showing the combined flow rate of two gasproducing reactions of FIG. 24A;

FIG. 25A is a diagram contrasting the flow rate of two gas producingreactions initiated at different times; and

FIG. 25B is a diagram showing the combined flow rate of two gasproducing reactions of FIG. 25A.

FIG. 26A depicts a pouch-type, self-contained, reaction chamberincluding separate compartments for the catalyst, gas/oxygen producingagent and water; and

FIG. 26B depicts another embodiment of a pouch-type, self-contained,reaction chamber including differently shaped, separate compartments forthe catalyst, gas/oxygen producing agent and water.

DETAILED DESCRIPTION

In the following discussion, numerous specific details are set forth toprovide a thorough understanding of the present invention. However,those skilled in the art will appreciate that the present invention maybe practiced without such specific details. In other instances,well-known elements have been illustrated in schematic or block diagramform in order not to obscure the present invention in unnecessarydetail. Additionally, for the most part, details concerning networkcommunications, electromagnetic signaling techniques, and the like, havebeen omitted inasmuch as such details are not considered necessary toobtain a complete understanding of the present invention, and areconsidered to be within the understanding of persons of ordinary skillin the relevant art.

Referring to FIG. 1 of the drawings, the reference numeral 100 generallydesignates an exploded view of a gas activation, production, dispensingand control assembly using a manual reaction activation method inaccordance with an embodiment of the present invention. The assembly 100comprises support housing 102, removable reaction chambers 106, screens108, filters 110, lids 112, and a handle 122.

The main body of the assembly 100 is the support housing 102. There area number of configurations that can be employed, but a convenient designis a vessel having vertically extending side walls and a bottom surfaceconnecting the side walls. The support housing 102 also has an openingin the top where other members can be inserted. The support housing 102can also be a smooth, continuous surface or it can be several joined,flat surfaces. For example, the support housing has a compartment foreach reaction chamber and can have curved surfaces such that it curvesaround the reaction chambers 106 in approximately the shape of a figureeight, as viewed from above. In such a configuration the gas activation,production, dispensing and control assembly 100 can be conveniently wornon the hip, by clip-on or otherwise of say, a miner, construction workeror emergency service personnel. Additionally, the support housing 102can employ two guides 104 that protrude outwardly from the side walls ofthe support housing 102 to interface with and/or slidably receive theguided members 114 of the handle 122. In the manual activation deviceshown in FIG. 1, the two guide members 104 allow the user to activatethe chemical reaction producing the oxygen or other gas, by pushing thehandle 122 in a direction toward the housing 102. The two guide members104 allow for this to be a smooth and easy process. Upon completion ofthe chemical reaction, the two guide members 104 similarly allow for asmooth and easy disengagement of the handle 122 in a direction away fromthe housing 102 utilizing a quick release mechanism 720 (depicted inFIG. 7, but not shown in FIG. 1). The support housing 102 can also actas an additional insulating material to act as a heat shield for anyexcess heat being generated in the reaction chambers.

Each of the reaction chambers 106 can be placed within the supporthousing 102 such that access can be gained to each reaction chamber 106.The reaction chambers 106 can be made of a durable thermoplastic withhigh tensile strength, high resistance to chemical reactions and highresistance to heat. For example, the reaction chambers 106 can be madeof polycarbonate or polytetrafluoroethylene. The lids 112 can beattached to the reaction chambers 106. For example, reaction chambers106 can have internal female threads and the lids 112 can havecorresponding external male threads. Alternatively, the lids 112 can beattached to the reaction chambers 106 by clip in, lock in or click indesigns. Screens 108 and filters 110 can be seated on a flange 107inside reaction chambers 106, but such is not essential to the design.For example, screens 108 and filters 110 can also simply be maintainedin position by mechanical pressure, or glued, as depicted in FIG. 3. Thereaction chambers 106 are typically cylindrically shaped, but can be anyother shape. The reaction chambers 106, however, can be coupled to thelids 112 prior to insertion into the support housing 102.

Referring to FIG. 2 of the drawings, the reference numeral 200 generallydesignates a primed gas production control vessel.

When the vessel 200 is in the primed position, gas production can beinitiated by engaging the handle 122. The guide members 104 (of supporthousing 102) can contain and guide the arms 114 of the handle 122. Byallowing the arms 114 to freely slide within the guides 104 a user wouldsimply place pressure on the handle 122 in a direction toward thesupport housing 102.

From the primed position, it is evident that alignment can be anadvantageous feature. Each of the spiked plungers 118 can be alignedwith an opening 116 of a lid 112. Therefore, when engaged, each of thespiked plungers 118 can be slidably inserted into each of the reactionchambers 106 to initiate the reaction and carry out the resultant gas.

Referring to FIG. 3 of the drawings, the reference numeral 300 generallydesignates a cut-away of a gas activation, production, dispensing andcontrol vessel in use.

When fully assembled, control of the gas production is achieved throughthe use of multiple reaction chambers 106. Two reaction chambers aredepicted, but there can be more reaction chambers depending on thedesired flow rate and yield. One reaction chamber can also be used.Chemical reactions occur in the lower portions 210 of the reactionchambers 106. By varying the proportion, amounts and/or composition ofthe reactants within the vessel, two different reaction rates (andyields) can be maintained independently in each of the reaction chambers106. Hence, each reaction chamber 106 can contribute a fractional gasoutput of the total gas output of the vessel, allowing for a variety ofgas yields and flow rates. Moreover, the reactants in each reactionchamber 106 can vary, as well, to achieve a desired gas yield and gasflow rate.

Each of the reaction chambers 106 rests within the support housing 102.Each of two guided members 114 of the handle 122 are inserted throughone of two guide members 104. Each of the reaction chambers 106 are thencoupled to the handle 122 by mechanical couplers 206. The mechanicalcouplers 206 can be a variety of mechanical coupler types, such asthreaded couplers or couplers employing snapping edges. Thus, thecombination of use of the guide members 104 and the couplers 206 allowfor a good mechanical connection during use.

Also while in use, spiked plungers 118 can be employed to allow gastransmission from the reaction chambers 106 to the gas transmissionchannel 202 of the handle 122. The spiked plungers 118 can each becoupled to the handle 122 within the gas transmission channel 202 of thehandle 122 and can each be inserted into a reaction chamber 106. Eachspiked plunger 118 can contact both the filter 110 and the screen 108.The screens 108 can be located at positions adjacent to the lowerportions 210, which allow gas to pass and provide mechanical support forthe filters 110. Because of the mechanical constraints of the mechanicalcouplers 206 and the guide members 104, the spiked plungers 118 can eachmaintain mechanical contact between the filter 110 and the screen 108.Gas produced within the lower portions of the reaction chamber 106 canthen pass around the tip of the plunger 118, through the screens 108,the filters 110, and into transmission openings 224 in spiked plungers118.

Once closed, each of the reaction chambers 106 and the lids 112, alongwith the reaction chambers' contents such as the gas/oxygen generatingmaterial, catalyst, water, screen and filter forms a self-containedcartridge 109 that can be disposable. Each self-contained cartridge 109is therefore easily replaceable if a user requires additional oxygen orgas (as the case may be) upon completion of a use. For example, the gasactivation, production, dispensing and control assembly 300 can bedesigned to produce 15 minutes of oxygen for emergency or short-durationpurposes. If the user requires additional oxygen at the end of that15-minute period, he/she can simply replace one or both the cartridges109 to have an additional 15 minutes of oxygen availability. Each usedcartridge 109 is simply discarded or recycled (if applicable) after use,allowing for simplicity and ease of use. Self-contained cartridges canbe attached to each other to form one removable, self-containedcartridge. The lids 112 can each have a cap to close the respectiveopenings 116, after the completion of the reaction. Closing the openings116 facilitates the prevention of any leakage of the reaction residueand thereby facilitates convenient disposal of the cartridges.

In reference to the self-contained cartridges 109 there are variousconfigurations possible in regards to the relative locations of thegas/oxygen releasing agent, the catalyst and the water, comprising theingredients used to make the reaction in the current invention work. Thegas/oxygen releasing agent, the catalyst and the water remain separateduntil a reaction is required. The gas/oxygen releasing agent and thecatalyst can remain inert and can have an indefinite shelf life if theyare kept dry and moisture free. One configuration example is to have thegas/oxygen releasing agent located at the base of the cartridge (inreaction chambers 106), the catalyst located above the gas/oxygenreleasing agent, and the water located above the catalyst, such as forexample in the plenums 111 of the lids 112. Upon activation, the wateris released and can flow in toward the lower portion of the reactionchamber 106, where the gas/oxygen producing agent (not shown) isdisposed, carrying the catalyst along with it through a flushing action,to mix with the gas/oxygen releasing agent at the base of the cartridge.We refer to this cartridge configuration as a water releasing cartridge.In this invention we will discuss different designs for water releasingcartridges. A different cartridge configuration, however, is one wherethe gas/oxygen releasing agent is located above the water and thecatalyst. In this cartridge configuration, the gas/oxygen releasingagent and/or the catalyst is/are released to mix with the water in orderto activate the reaction. We refer to this cartridge configuration as achemical releasing cartridge.

In either cartridge configuration, once a chemical reaction isinitiated, the resultant gas can carry small airborne droplets of thegas production solution, or can carry small particles from thereactants. These airborne particles can be undesirable to the equipmentattached to the gas generator or to the lungs of an individual.Therefore, there is a need to filter these undesirable particles. Thereare several methods that can be used to filter such undesirableparticles. Methods that can be used include selecting appropriatematerials to capture the undesirable particles, and to select anappropriate configuration by locating the selected materials in anappropriate location, relative to other components in the invention.Therefore, material selection and placement can be important factors.However, the filter material employed depends on the gas produced, thecomposition of the solution, and the usage of the gas. In reference toFIG. 1, the filters 110 can be sponge-like materials to capture theundesirable particles, while allowing the gas to flow through atdesirable flow rates. Other effective filter materials can bepolytetrafluoroethylene or can be Nylon®, which is available fromDuPont. In addition to absorbing or filtering out undesirable particles,filters can also be useful in extracting some heat out of the gas beingproduced, either in their untreated form, or by being treated withvarious substances.

FIG. 4 depicts an example of a screen that can be used. The screens 108can serve to support the filters 110, while allowing the water torapidly and evenly disperse into the reaction chambers 106, in order toactivate the chemical reaction that produces the oxygen or gas, as thecase may be.

In order to allow fluid transfer through the screen 108, several openingcan be provided. The edges of the screen 108 would rest against theinner walls of a reaction chamber 106 or on a surface within thereaction chamber 106. Fluids would then be allowed to pass through theopenings 404, 402, and 406. Additionally, when engaged, the spikedplungers 118 would at least partially reside within the opening 402.

Referring to FIGS. 5A, 5B, and 5C of the drawings the reference numeral500 generally designates a foam breaker. FIG. 5A depicts a crosssectional view of the foam breaker 500, where the opening 502 wouldallow the spiked plunger 118 to reside when engaged. FIG. 5B depicts aside view of the foam breaker 500, and FIG. 5C depicts a side view ofthe foam breaker 500 when compressed.

Chemical reactions can produce foam, and a foam breaker 500 cancounteract this effect. For example, a steel mesh with an appropriatemesh size can be used. Another material that can be used as a foambreaker is a commonly used pot scourer or scrub sponge material, ordurable foam material. The foam breaker can be optionally placed withinthe same fluid transmission path in which both. the screens 108 and thefilters 110 reside. The screens 108 can also act as foam breakers, andthe filters 110 can also act as foam breakers. The screens 108 andfilters 110, acting together can also act as foam breakers.

Another method is to apply a defoaming agent or surfactant to the wallsand/or the screen and/or the lid and filter. Defoaming agents that canbe used include silicone based, polymer based or mineral oil basedagents, as well as other surfactants. Regardless of where the foambreaker or defoaming agent is placed in the device, the filter shouldfollow the foam breaker or defoaming agent (as considered in thedirection of the gas flow).

Referring to FIG. 6 of the drawings, the reference numeral 122 generallydesignates the handle. The handle 122 effectively operates as amanifold. Especially in situations where multiple reaction chambers areused, it is desirable to have a manifold or similar method of combiningthe gas flow from each individual reaction chamber 106. The manifold gastransmission channel 202 performs the function of combining gases, andthe gas flows from each reaction chamber 106 into the ports 602. Thegases are then combined in the manifold gas transmission channel 202.

Upon activation, however, the spiked plungers 118 should provide acontinuous gas transmission to the manifold gas transmission channel202. The mechanical coupler 206 can secure lids 112 in such a manner asto seal off the opening 116 of the lids 112 and maintain the connectionbetween the spiked plunger 118 and the handle 122. Specifically, themechanical coupler 206 can be a simple coupler 206 to which the nozzle116 of the self-contained cartridge 109 is inserted, as depicted in FIG.3 In another embodiment, the couple 206 or can comprise a cooperativelydesigned male connector adapted to fit over the nozzle 116, as depictedin FIG. 8, and a female connector adapted to fit into the maleconnection, as depicted in FIGS. 7, 9, 10B and 10C.

With initial reference to FIG. 7, e the reference numeral 700 refers tothe female connector. The female connector 700 is typically attached tothe spiked plunger 118, where the spiked plunger 118 is inserted intothe opening 704 of the female connector 700. Additionally, as depictedin FIGS. 14 and 15, the female connector couples to the ports 602 of thehandle 122. When engaged, the female connector 700 snaps into place. Thefemale connector 700 comprises an arm 702 that possesses an engagementedge that allows for coupling to a male connector. Additionally, thefemale connector 700 can be made of various materials, including,without limitation polypropylene, polyethylene, polycarbonate, HDPE,ABS, Acetal, or Polysulfone.

Referring to FIG. 8 of the drawings, the reference numeral depicts amale connector. FIG. 8 is a side view of the male connector 800, withthe O-ring seal shown in cross-section for clarity.

The male connector 800 is a cylindrical tube that is able to engage thefemale connector 700. The male connector can comprise an O-ring 802, anupper edge 804, and a lower edge 806. The O-ring 802 is responsible forproviding a gas seal between the male connector 800 to the femaleconnector 700 the the male connector 800 is inserted into the femaleconnector during use. The O-ring can be made of various materials,including, without limitation, silicone or platinum-cured silicone.Platinum-cured silicone can allow for repeated usage of more than onethousand times. The lower edge 806 can engage the edge of the arm 702 bya clicking action. To more conveniently allow for the clicking action totake place, a slanted engaging face 808 is employed. Additionally, theupper edge 804 prevents excessive play by providing a stop for the edgeof the arm 702. The male connector can also be made of variousmaterials, including, without limitation polypropylene, polyethylene,polycarbonate, HDPE, ABS, acetal, or polysulfone.

The male connector 800 can then be secured to the lid 112 by usingthreads. Typically, the lid 112 is coupled to the male connector throughthe opening 810. Therefore, female threads would be contained on theinner walls of the male connector 800 while the male threads would becontained on the lid 112.

Once the reaction is completed, the female connector 700 and the maleconnector 800 can be easily and quickly disengaged. The quick releasemechanism 720 can be coupled to the arm 702 of the female coupler 700.By pressing the quick release mechanism 720 in the direction toward theplane created by the azimuthal axes of the spiked plungers 118, the maleconnector and the female connector can be disengaged. Additionally, thequick release mechanism 720 can be configured to disengage the femaleconnectors 700 from the male connectors 800 by simply gripping the quickrelease lever 128 in a direction toward the handle 122.

For applications such as emergency applications it is desirable to havean efficient and easy activation method, which is simultaneouslymanufacturable and economical. For such emergency applications, theactivation method should be such as to commence the chemical reactioninstantaneously or near instantaneously with typically one easy step.For example, activation can be achieved by a single push-down actionthat applies pressure to the handle 122. A system can also be electronicor a sensor, such as for example a system used to detect decompressionin aircraft, thereby triggering the deployment of emergency oxygen inthe aircraft cabin.

In one embodiment, during activation of the chemical reaction, thespiked plungers 118′ are each inserted into lids 112. The spiked plunger118 and 118′ are typically hollow cylindrically-shaped members that havea tip that is suitable for and utilized to puncture a material.Referring to FIG. 9 of the drawings, the reference numeral 900 generallydesignates one embodiment of the connectable spiked plunger.

Specifically, the connectable spiked plunger 900 comprises a femaleconnector 700 and a spiked plunger 118. The spiked plunger 118 cancomprise a cylindrically-shaped shaft 906 with a spiked end 904. Withinthe spiked plunger 118 is a gas transmission channel 902 along theazimuthal axis of the spiked plunger 118 that allows gas to travelthrough the plunger 900. Additionally, transmission openings 224 areemployed to allow the gas transmission channel 902 to be in fluidcontact with gas outside of the spiked plunger 118.

In particular the plunger 900 is designed to puncture a materialcontainer or containment bag to initiate a chemical reaction. Forexample, the spiked plunger 118 can puncture a container or bag thatcontains water, or the spiked plunger 118 can be used to puncture amembrane or other material, causing the release of water or chemicals,as the case may be. The spiked plungers 118 can be made of durablethermoplastic with high tensile strength, high resistance to chemicalreactions and high resistance to heat. For example, the spiked plungers118 can be made of polycarbonate.

In another embodiment, an extended spiked plunger can be employed.Referring to FIGS. 10A, 10B, and 10C, the reference numeral 1000generally designates an extended spiked plunger 118′.

Specifically, the plunger 118′ can comprise a female connector 700 and aspiked plunger 118′. However, the spiked plunger 118′ is different inthat it is extended. The spiked plunger 118 comprises a torso 1002 andan extension shaft 1004 with a sharp tip 1006. The torso 1002 can becylindrically shaped and employ a gas transmission channel 902 along theazimuthal axis of the torso 1002 that allows gas to travel through theplunger 118′. Additionally, transmission openings 224 can be employed toallow the gas transmission channel 902 to be in fluid contact with gasoutside of the spiked plunger 118′.

Attached at the end of the torso 1002 is the extension shaft 1004. Theextension shaft 1004 can be cylindrically-shaped with one end insertedinto the female receptive aperture 1008 at the end of the torso 1002.The sharp tip 1006 can then be attached to the other end of theextension shaft 1004.

In particular, the plunger 1000 is designed to puncture a materialcontainment container or bag to initiate a chemical reaction. Forexample, the spiked plunger 118 can puncture a container or bag thatcontains water, or the spiked plunger 118 can be used to puncture amembrane or other material, causing the release of water or chemicals,as the case may be. The spiked plungers 118 can be made of durablethermoplastic with high tensile strength, high resistance to chemicalreactions and high resistance to heat. For example, the spiked plungers118 can be made of polycarbonate.

In yet another embodiment, an initiator can be employed as apush-button, lever or pin. An initiation system can also be electronicor a sensor, such as for example a system used to detect decompressionin aircraft, thereby triggering the deployment of emergency oxygen inthe aircraft cabin. Referring to FIG. 11 of the drawings, the referencenumeral 1100 depicts a spring loaded spiked plunger 1118.

The spring loaded spiked plunger 1118 then can utilize potential energystored in a spring to extend its sharp tip 1110 into the containers ofwater and/or chemicals to begin the chemical reaction that produces thegas. The spring 1106 can be maintained within the spring housing 1114and held in place by a retainer 1104. The process of initiating thechemical reaction would involve the utilization of an actuator 1102,which is shown as a push-button actuator. The actuator 1102 causes theretainer 1106 a lever arm 1107 to pivot about pivot 1109, pulling outpin 1104 to release the spring 1106. The spring 1106 then exerts a forceon the spiked plunger 1118.

The spiked plunger 1118 can comprise a cylindrically shaped shaft with aspiked end 1110. Within the spiked plunger 1118 is a gas transmissionchannel 902 along the azimuthal axis of the spiked plunger 1118 thatallows gas to travel through the plunger 1118. Additionally,transmission openings 224 can be employed to allow the gas transmissionchannel 902 to be in fluid contact with gas outside of the spikedplunger 118.

In particular, the plunger 1118 is designed to puncture a materialcontainment container or bag to initiate a chemical reaction. Forexample, the spiked plunger 1118 can puncture a container or bag thatcontains water, or the spiked plunger 1118 can be used to puncture amembrane or other material, causing the release of water or chemicals,as the case may be. The spiked plungers 1118 can be made of durablethermoplastic with high tensile strength, high resistance to chemicalreactions and high resistance to heat. For example, the spiked plungers1118 can be made of polycarbonate.

There are several other types of systems that can be employed toinitiate a gas generating chemical reaction. An actuator can utilize thepressure associated with a chemical release cartridge. A pressure supplycan also be achieved by supplying air pressure to the activation system.Another type can be a mechanical or electromechanical source, such ascan be provided by a mechanical or electromechanical pump or motor. Yetanother type can be a pneumatic source, such as for example a pneumaticpump or motor, or a hydraulic source.

Depending on the type of gas producing reaction, pressures in thereaction chamber 106 can be high and dangerous. Referring to FIG. 12 ofthe drawings the reference numeral 1200 generally designates a cartridgewith a relief system. The cartridge 1200 comprises a reaction chamber106, a screen 108, a containment bag 1202, a filter 110, and a lid 112.

When in storage or not in use, the reaction chamber 106 contains “dry”reactants. The “dry” reactants typically include an oxygen rich powderreactant, such as sodium carbonate or sodium percarbonate, as thegas/oxygen generating agent. However, the dry reactants can be liquidreactants that require an additional solvent, such as water, or other“wet” chemical to initiate a gas producing reaction. These “dry”reactants can also contain “dry” catalysts that can assist in reducingheat or increase the reaction rate, such as manganese dioxide. There arealso be a number of other catalysts that can be employed for a varietyof other purposes. In addition, it should be noted that the water caninclude an additive to depress the freezing point of the water, but neednot do so. Inserted into the reaction chamber 106 is the screen 108. Thescreen 108 is mechanically supported in a position adjacent to thecavity containing the “dry” reactants. The screen 506 can bemechanically supported in a number of ways, such as by use of threading,snapping edges, and/or taper of the inner walls of the reaction chamber106.

The screen 108 can provide mechanical support for the remainingcomponents contained within the cartridge 1200.

A containment bag 1202 is positioned adjacent to the screen 108, sothat, when pierced, the contents of the bag 1202 can be transmittedthrough the screen to the “dry” chemicals to begin the reaction. Thefilter 110 is also supported by the screen 108, so that when gas isproduced and transmitted through the screen 506, the gas can befiltered. A variety of filter types can be employed that can becomprised of a variety of materials including, but not limited to,polytetrafluoroethylene.

The final component of the cartridge 1200 is the lid 112. The lid 512can be coupled to the reaction chamber 106. There are a number of waysto couple the lid 112 to the reaction chamber 106, such as threading andan adhesive.

An additional feature of the cartridge 1200, however, is the presence ofa pressure relief valve 1214. In cases where high pressure, volatilegases are produced, such as oxygen or hydrogen, high pressures can bedangerous. Even in situations where gases do not present a fire hazard,such as nitrogen, high pressures can be an undesirable because the highpressure gas can exploit defects or fractures in the cartridge 1200 tocause the cartridge to rupture. To relieve pressure within the cartridge1200, a relief valve 1214 can be employed to relieve pressure within thechamber at a calibrated level. For example, pressure relief can occur at300 psig. There are a wide variety of pressure relief systems available,such as pop-off valves and rupture discs that can be adequatelycalibrated to relieve pressure at a desired level.

There are also alternative arrangements for containing the materialsemployed to sustain the chemical reaction. Referring to FIGS. 13A and13B of the drawings, the reference numerals 1300 and 1350 depict anactivation system primed for activation and the system in use,respectively.

The system 1300 comprises a cartridge 1301, a spiked plunger 118, and afemale connector 700. The cartridge 1301 then comprises a filter 110,water-filled bag 1304, a screen 108, a catalyst filled bag 1306, and agas releasing agent 1308 contained within a reaction chamber 106 and alid 112.

The bag housing the catalyst 1306 can be made of any number ofmaterials, but can also be made of a water-soluble material. The bag1304 housing the water can be made of any number of air impermeable andwater/moisture impermeable materials, but can also be made of a laminatematerial consisting of aluminum, polypropylene and woven mesh.

The cartridge 1301 typically also has an air-impermeable andwater-impermeable seal 1302. The air-impermeable and water-impermeableseal 1302 can be made of various materials, including, withoutlimitation materials such as Mylar, polytetrafluoroethylene or Nylon®.The purpose of the seal 1302 is to maintain an hermetic seal so that thecartridge can have an extended or indefinite shelf life.

Upon activation, the spike tip 904 punctures or ruptures the seal 1302,and the spiked plunger 118 enters the filter aperture 1320. At thatpoint, the spike tip 904 punctures or ruptures the water bag 1304,causing the water to flow into the reaction chamber 106. The spikedplunger 1130 completes the piercing of the water bag 1172 and proceedsthrough the screen aperture 402 such that the spike tip 1142 protrudesjust slightly beyond the screen 108. Once the spiked plunger 1130 haspenetrated the water bag 1172 and traversed all the way through, spikedplunger and connector assembly 1140 is secured to the cartridge andsealed by the connector 1180.

Once released, the water creates an aqueous environment for the reactionto take place. The water dissolves the bag containing the catalyst 1306.The gas generated as a result of the reaction can then be released fromthe cartridge 1301 through the spiked plunger 118.

Another embodiment of the cartridge 1301 includes a hanging catalystbag. Referring to FIG. 14 of the drawings, the reference 1400 generallydesignates a release system with a hanging catalyst. The system 1400comprises cartridges 1401, a handle 122, and cutting members such asspiked plungers 118. Within the cartridges 1401, there is an upperassembly 1402, a hanging catalyst 1404, and a gas generating chemical1308.

Upon activation, the spiked plunger 118 engages the upper assembly 1402.Water then flows into the reaction chamber 106. The water creates anaqueous environment for the reaction to take place, while dissolving orpermeating the bag containing the catalyst 1404. The gas generated as aresult of the reaction can then be released from the cartridge 1401through the spiked plunger 118 to the gas transmission channel 202 ofthe handle 122. The bag housing the catalyst 1404 is suspended slightlyabove the gas generating material 1308, which facilitates fasterdissolution of the bag if the bag is a water-soluble bag, or fasterpermeation through the bag if the bag is permeable.

Referring to FIG. 15, the reference number 1500 depicts another systemprimed for activation. The system 1500 is different in that the catalystis contained in a catalyst dispersal housing 1502, located just belowthe water containment housing 1504. The water containment housing 1504can contain a bag with water, or can have water contained inside of it.

The system 1500 can comprise self-contained water releasing cartridge1501, a spiked plunger 118, and a connector assembly 700 coupled to thehandle 122. The cartridge 1501 comprises a gas or oxygen releasing agent1308, the catalyst dispersal housing 1502, the screen 108, and the watercontainment housing 1504. If the water is contained in a bag, the bagcan be made of any number of impermeable materials, but can also be madeof a laminate material consisting of aluminum, polypropylene and wovenmesh.

Upon activation, the spiked plunger 118 engages the water containmenthousing 1504 and the catalyst dispersal housing 1502. Water then flowsinto the reaction chamber 106. The water creates an aqueous environmentfor the reaction to take place. The gas generated as a result of thereaction can then be released from the cartridge 1301 through the spikedplunger 118 to the gas transmission channel 202 of the handle 122.

A desirable feature of the system 1500 is the construction of the watercontainment housing 1504 and the catalyst dispersal housing 1502.Referring to FIG. 16A of the drawings, the reference numerals 1504 and1502 generally designate the water containment housing and the catalystdispersal housing, respectively. Specifically, water containment housing1504 and catalyst dispersal housing 1502 assembly can be made as onepiece, and can be made of any material. Without limitation, the watercontainment housing and catalyst dispersal housing assembly can be madeof plastic or thermoplastic, including polypropylene, polyethylene,polycarbonate, HDPE, ABS, acetal, polysulfone, or poly vinyl chloride(PVC).

The water containment housing 1504 and the catalyst dispersal housingare designed such that it can be a self-contained unit. The watercontainment housing 1504 has an upper aperture 1602 covered by an uppersealing membrane 1604 and has a lower aperture 1606 covered by a lowersealing membrane 1608. A spiked plunger can be inserted through theseals 1604 and 1608 and the apertures 1602 and 1606 upon activation. Thecatalyst dispersal housing 1502 also has an aperture 1612 covered by acatalyst housing seal 1610, which allows the spiked plunger 118 tofinally exit the catalyst dispersal housing 1502 during the activationprocess.

Prior to activation, the water is sealed into the water containmenthousing 1504 by upper seal 1604 and lower seal 1608. While the upperseal 1604 and the lower seal 1608 are shown as having been placed on topof each respective adhesion surface, each can be also be placed on thebottom side of each respective adhesion surface. Catalyst housing seal1610 can also be placed on either side of the adhesion surface. Each ofthe seals 1604, 1608, and 1610 can be made of air-impermeable andwater-impermeable materials, including, without limitation materialssuch as polytetrafluoroethylene, Mylar®, or Nylon® (both available fromDuPont).

During activation, the water is released from the water containmenthousing 1504 and proceeds in a direction towards the reaction chamber106, flushing the catalyst with it. Referring to FIG. 16B, the catalystdispersal housing 1502 can have an angled or beveled surface 1614, whichfacilitates faster and more efficient dispersal of the catalyst and/orwater. Additionally, the water containment housing 1504 can also havecontain an angled or beveled surface in order to facilitate faster andmore efficient dispersal of the water upon activation. The angled orbeveled surface 1614 can facilitate better flushing of the catalyst,and/or facilitate faster and more efficient dispersal of the catalyst.

The self-contained housings can also include an in-place spike.Referring to FIGS. 17A and 17B of the drawings, the reference numeral1700 generally designates an alternative design of the self-containedhousings. Specifically, a plunger 1702 with an upper seal 1704, a lowerseal 1706, and catalyst housing seal 1708 is employed. The seals 1704,1706, and 1708 are attached to the plunger 1702 such that the seals1704, 1706, and 708 do not break away from or separate from the plunger1702 during normal use. The seals 1704, 1706, and 1708 are attached tothe water containment housing 1504 and catalyst dispersal housing 1502such that the seals 1704, 1706, and 1708 are breakable, detachable, orremovable upon activation.

FIG. 17A depicts the self-contained housings 1700 in a primed position.Upon activation, the downward force transferred by the pressure sourcerips, tears, dislodges or otherwise detaches the seals 1704, 1706, and1708, causing the contents to flow into the reaction chamber 106.Stoppers 1710 allow the plunger 1702 to travel only a specifieddistance.

An alternative activation method can involve a chemical releasecartridge bag configuration. Referring to FIGS. 18A and 18B, thereference numeral 1800 generally designates a pouch that employs amethod for storing the gas/oxygen releasing agent and the catalyst.

Accordingly, there is a planar sealed pouch 1800 formed of air- andwater-impermeable sheet material 1802 which is resistant to the basicchemicals commonly used. The sheet material 1802 supports the gas/oxygenreleasing agent 1804 and has a web seam 1806 whose apex points upwardlytowards the gas/oxygen releasing agent 1804. The sheet material 1802 hasa base seam 1808 parallel to and below the web seam 1806. The base seam1808 then seals the pouch 1800. The region between the web seam 1806 andthe base seam 1810 forms a compartment 1810 into which catalyst 1809 isdisposed.

The entire contents of the pouch 1800 are designed to be released in arapid fashion into water contained in an outer container in which thepouch 1800 is contained, such as container 106. Therefore, it is thoughtthat the web material 1810 is to be a non-permeable laminar sheet sothat none of the chemical material escapes into the volume below the webmaterial. Additionally, the web seam 1806 is formed with a pressuresensitive seal which is broken when pressure is applied.

The pouch 1800 is constructed using a continuous sheet of water- andair-impermeable sheet material 1802 folded such that the fold, situatedin the middle of the sheet, fits over and advantageously accommodatesthe nozzle element 1812. The water- and air-impermeable sheet material1802 is welded together at side seams 1816 and bottom seam 1808, and thesheet material 1802 can be a multi-layer laminate such as (from insideto outside) polyester, aluminum foil, polyester and polypropylene. Itshould be noted that side seams 1816 can also be frangible during use,like seam 1808, but need not be.

During use, water or air is introduced into the pouch cartridge by meansof a hollow injector inserted into the delivery channel 1814 throughmembrane 1805. The pressure causes the web material to evert inside-outto vent by rupturing the pressure-sensitive seal at 1806. Thus, thegas/oxygen releasing agent 1804 is released through an opening made inthe web seam 1806. The catalyst is simultaneously released through theweb seam 1806. Because of the geometrical shape of area 1810, therupturing of seal 1806 occurs in a predictable and reproducible manner.Once the gas has been produced, humidification and/or cooling/warming ofthe gas may be required.

Referring to FIG. 19 of the drawings, the reference numeral 1900generally designates a bubbler. The bubbler 1900 comprises a liquidholding tank 1902, an intake tube 1904, an exhaust tube 1906, and aliquid 1908.

During the operation, the gas is bubbled through the liquid. Because gasinput pressure into the bubbler 1900 is higher than atmosphericpressure, the gas can be forced through the intake tube 1904. Part ofthe intake tube 1904 is submerged within the fluid 1908, the exhaust gasbubbles through the liquid 1908. The effect of traveling through theliquid 1908 is that the gas will transfer heat to the liquid 1908(cooling) or receive heat from the liquid 1908 (warming).

Once the gas has bubbled to the surface, the gas can then exit throughthe exhaust tube 1906. When the gas exists, it is likely that smalldroplets of the liquid can be carried with the gas. Additionally, vaporsof the liquid can also be carried. In the case of oxygen production, theoxygen can be cooled or warmed through water. Once bubbled, the oxygenwould carry water vapor, thus, producing humidified oxygen.

Another design to cool or warm a gas is by use of a radiator. Referringto FIG. 20 of the drawings, the reference numeral 2000 generallydesignates a radiator. The radiator comprises fins 2004 and a radiatortube 2002.

As gas is output, a heat sink is employed to transfer heat. The gas isinput into the radiator tube 2002 to snake through the radiator 2000. Asthe gas progresses through the radiator 2000, heat is transferred to thefins 2004. The fins 2004 then transfer heat to a larger heat sink. Thelarger heat sink can be a variety of heat sinks which includes, but isnot limited to, the atmosphere.

One of the features of the above referenced devices is the ability toutilize multiple reactions chambers. Having multiple reaction chamberscreates the ability to increase the performance of the gas dispenser,without the associated increase in pressure and temperature if only onereaction chamber is used. For example, a reaction that produces 90liters of oxygen in 15 minutes can experience an exponential increase inpressure, especially after a certain internal (to the reaction)temperature is reached. By splitting this same reaction into tworeactions, completely isolated from each other in separate chambers(say, of each producing 45 liters over 15 minutes), a stable delivery ofgas is produced without the exponential increase in pressure and/ortemperature that can result from the same 90 liter reaction over 15minutes contained in one chamber with one reaction.

Similarly, a much higher degree of control is possible over the increasein temperature of the gas by splitting the reaction into multiplereactions. Normally, reactions such as the exothermic reactions thatgenerate oxygen, create heat and a concomitant increase in pressure in astatic volume (i.e. there is a direct correlation between temperatureand pressure). A further benefit of using multiple reaction chambers isthat a higher reaction onset can be achieved.

Specifically, any multiple of reaction chambers can be combined tocreate any desired output of volume, flow rate and/or delivery time. Forexample, 3 reaction chambers, each producing 30 liters of oxygen can becombined to produce the same 90 liter reaction, but with loweredpressure inside each reaction chamber and reduced temperature increaseof the generated gas, relative to using the same quantity of reactantsand catalyst in only one or two chambers, for example.

Variations in both flow rate and yield can also be varied or dictated bythe compositions of the contents in the reaction chambers 106. Forexample, by varying the amount of a limiting reactant in each chamberand/or by varying the amount and/or composition of the catalystcontained in each cartridge, different flow rates and gas yields can beachieved. For example, by varying the amount of the sodium percarbonatein an oxygen generation reaction in each of the chambers, a yield of 90liters with a flow rate of 6 liters per minute for 15 minutes or a yieldof 30 liters and a flow rate of 3 liters per minute for 10 minutes canbe achieved.

The flow rates and yields can be varied depending on the desired usageand can be for different situations, such as emergency oxygen foraircraft or mines. While there are many possible or acceptable flow rateprofiles applicable to the aviation industry, one example may be to havea reaction that produces approximately 4 liters per minute for 4 minutesand then drops to 1 liter per minute for 8 minutes. Using 2 reactionchambers can achieve this general performance profile.

Additionally, there are several other configurations that can beemployed to store the chemicals. Referring to FIG. 21 of the drawings,the reference numeral 2100 generally designates a cartridge 2100. Thecartridge 2100 comprises a lid 1126 and a reaction chamber 106.

When combined, the reaction chamber 106 and the lid 112 contain a filter110, a foam breaker 500, a screen 108, water 2104, a gas producing agent2102, and a catalyst 2106. The filter 110 and the foam breaker 500 arelayered on top of the screen 108, and the chemicals 2106, 2102, and 2104are contained within the lower portion of the reaction chamber 106. Thewater 2104 rests at the bottom of the reaction chamber 106, being heldin place by frangible seal 2108. The catalyst 2106 and the gas producingagent 2102 are each contained on a side of the reaction chamber, held inplace by a frangible seal 108.

Upon activation, the frangible seals 2108 are broken. The chemicals2102, 2104, and 2106 then mix to create a gas generating reaction. Thegas produced traverses the screen 108, the foam breaker 500, and thefilter 110 to exit the cartridge 2100.

Referring to FIG. 22 of the drawings, the reference numeral 2200generally designates a cartridge. The cartridge 2200 comprises a lid 112and a reaction chamber 106.

When combined, the reaction chamber 106 and the lid 112 contain a filter110, a foam breaker 500, a screen 108, water 2204, a gas producing agent2202, and a catalyst 2206. The filter 110 and the foam breaker 500 arelayered on top the screen 108, and the chemicals 2206, 2202, and 2204are contained within the lower portion of the reaction chamber 106. Thewater 2204, the catalyst 2206, and the gas producing agent 2202 eachrest at the bottom of the reaction chamber 106. Each of the chemicals2202, 2204, and 2206 are separated from one another and held in place bya frangible seals 2208.

Upon activation, the frangible seals 2208 are broken. The chemicals2202, 2204, and 2206 then mix to create a gas generating reaction. Thegas produced traverses the screen 108, the foam breaker 500, and thefilter 110 to exit the cartridge 2200.

Referring to FIGS. 23A and 23B of the drawings, the reference numeral2300 generally designates a self-contained activation system. The system2300 comprises a container 2302 and an activation handle 2304. Thesealed unit 2302 is particularly adapted for containing one or morepouches 26000 or 2600′, depicted in FIGS. 26A and 26B. However, sealedunit 2302 can also contain a multitude of devices, such as theconfigurations of FIGS. 1-3, 12-18, and 21-22, capable of releasing agas. To initiate the release of a gas, the activation handle 2304 isdisplaced downwardly into an activation position to apply mechanicalpressure to any of the multitude of devices to break any seals andinitiate the chemical reaction(s). Additionally, the activation positionof the handle 2304 can be reached by being displaced into either anupward or a downward position relative to the container 2302.

Referring to FIG. 24A of the drawing, the reference numeral 2400generally designates a diagram contrasting two gas producing reactions.The first reaction (REACTION 1) is set up to produce a short reactionthat starts high but is only maintained for a short period. The secondreaction (REACTION 2) is set up to start slow but to be maintained for alonger period.

Considered individually, neither REACTION 1 in the first reactionchamber nor REACTION 2 in the second reaction chamber produce thedesired flow rate profile. However, referring to FIG. 23B of thedrawings, the reference numeral 2450 generally the combined output ofREACTION 1 and REACTION 2. The combined output 2450 shows the sum of thecombined reactions 1 and 2, and illustrates how the desired profile isachieved using 2 reaction chambers instead of one.

Similarly, other profiles can be achieved by two reaction chambers ormultiple reaction chambers. For mining applications, for example, onepossible flow rate profile is to simply maintain a reaction at anaverage of 2 liters per minute for 60 minutes.

Another advantage of multiple reaction chambers is that the reactionscan be staged to commence at different times in order to achieve adesired output. Referring to FIG. 25A of the drawings, the referencenumeral 2500 generally designates a diagram showing two contrastedreactions. The diagram 2500 shows two identical reactions, REACTION 3and REACTION 4, each with a reaction onset of 1.75 liters per minute.Each of REACTION 3 and REACTION 4 can take place in respective reactionchambers. In this case, the reactions are staged such that Reaction 3commences at time=0 and runs for 12 minutes, while Reaction 4 commencesat time=10 minutes.

Referring to FIG. 25B of the drawings, the reference numeral 2550 showsa diagram depicting the combined outputs of REACTIONS 3 and 4.Considered individually, neither REACTION 3 in the first reactionchamber nor REACTION 3 in the second reaction chamber may produce thedesired flow rate profile. However, the output of the combinedreactions, shown in the diagram 2550 shows a 20-minute production withflow rates in a relatively narrow range, as the trend-line indicates.

By using multiple reaction chambers and/or staging reactions to commenceat different times, a wide variety of flow rates, volume, time periodsand performance profiles can be achieved, which allows for superiorperformance flexibility. This makes it possible for the currentinvention to cater effectively to a very broad range of applications,such as mining, aviation, emergency medical services, the military,emergency home use or any number of other applications on a worldwidebasis, and to customize the flow rate profile that is optimum for theparticular application.

FIG. 26A depicts an embodiment of a planar sealed pouch that employs amethod for storing the gas/oxygen releasing agent, the catalyst and thewater all in one pouch. Planar sealed pouch 2600 is formed of a pair ofsheets 2602 of air- and water-impermeable sheet material which isresistant to the basic chemicals commonly used (only the top sheet 2602being visible in FIG. 26A). The sheet material 2602 supports thecatalyst in compartment 2604, the gas/oxygen releasing agent incompartment 2606 and the water in compartment 2608. The sheet materialmust be resistant to the chemicals of the catalyst, gas/oxygen releasingagent and the water. In one embodiment, the sheet material is a laminatematerial that can be any combination of aluminum, polypropylene,polyethylene terephthalate, polyethylene, high density polyethylene, andany number of materials. The laminate material can also include a layerof insulating material. The pouch 2600 has a peripheral border 2611which is sealed by convenient means, such as adhesive, ultrasonicwelding, or heat sealing and is able to retain the pressures encounteredwithout bursting.

Each of the compartments 2604, 2606 and 2608 also have internal sealedborders 2612 to retain their respective chemicals so that they stayinitially separated. Unlike peripheral border 2611, sealed borders 2612are sealed with a pressure-frangible adhesive to create “peel areas”between the top and bottom sheet material 2610. In this embodiment, thecompartments 2604, 2606 and 2608 do not take up all of the area of thesheet material 2602, thus also defining an initially empty compartment2607. For reasons to be explained, empty compartment 2607 may also beinitially filled with air at ambient pressure.

The pouch 2600 accommodates nozzle element 2614, which can be made ofsuitable plastic such as polypropylenene, to permit the release of theoxygen or other gas produced. Because the gas produced may includeentrained droplets of water or particulates from the catalyst andgas/oxygen producing agent, the pouch also includes self-containedpermeable membrane/screen 2616 and a foam breaker 2618 that is retainedby the membrane/screen 2616. When the gas/oxygen is produced, it willpass through the membrane/screen 2616 and the foam breaker 2618, whereis effectively filtered, removing any entrained water droplets, bubblesor particulates before being exhausted from nozzle 2614 and directedthrough an appropriate conduit (not shown) to the user.

To use pouch 2600, force is applied to the outside of the pouch 2600,either directly or by means of the mechanism depicted in FIGS. 23A and23B. This force causes internal pressure in the pouch, much likeattempting to pop a balloon. Because the peripheral seal 2611 ispressure-resistant, seal 2611 does not burst. However, this internalpressure tends to cause sealed borders 2612 to peel apart, allowing thetop and bottom sheets of the sheet material 2602 to separate andallowing the initially separated catalyst, gas/oxygen releasing agentand water to combine to create gas. It is believed that having somedegree of air in initially empty compartment 2607 will tend tofacilitate the peeling apart of these sealed borders 2612 by more evenlydistributing the pressure, but this is not necessary to the invention.

FIG. 26B depicts another embodiment of a pouch having compartments forinitially separating the catalyst, oxygen producing agent and water. InFIG. 26B, pouch 2600′ is similar to pouch 2600, the compartments 2604′,2606′ and 2608′ containing, respectively, the catalyst, oxygen producingagent and water, and the initially empty compartment 2607′ containingair. In pouch 2600′, however, each of the compartments have differentshapes and locations. As in pouch 2600, each of the compartments isseparated by pressure-frangible sealed borders 2612′, constructed in thesame manner.

The pouch 2600′ accommodates nozzle element 2614, which can also be madeof suitable plastic such as polypropylenene, to permit the release ofthe oxygen or other gas produced. Because the gas produced may includeentrained droplets of water or particulates from the catalyst andgas/oxygen producing agent, the pouch also includes self-containedpermeable membrane/screen 2616 and a foam breaker 2618, that is retainedby the membrane/screen 2616, to filter the gas generated. Otherwise, theconstruction and operation of the pouch 2600′ is the same as pouch 2600and need not be further described.

It should be noted that, as is the case with the multiple reactionchambers 106 depicted in FIG. 1, for example, multiple ones of pouches2600 and/or 2600′ may be connected to a common conduit and usedtogether. Each of the pouches 2600 and/or 2600′ can contain differentcompositions or proportions of the water, catalyst and gas/oxygenproducing agent, as previously described, in order to create variousflow profiles such as are depicted in FIGS. 24B and 25B.

It is understood that the present invention can take many forms andembodiments. Accordingly, several variations may be made in theforegoing without departing from the spirit or the scope of theinvention. The capabilities outlined herein allow for the possibility ofa variety of implementations. This disclosure should not be read aspreferring any particular embodiments, but is instead directed to theunderlying mechanisms on which these embodiments can be built. Havingthus described the present invention by reference to certain of itspreferred embodiments, it is noted that the embodiments disclosed areillustrative rather than limiting in nature and that a wide range ofvariations, modifications, changes, and substitutions are contemplatedin the foregoing disclosure and, in some instances, some features of thepresent invention may be employed without a corresponding use of theother features. Many such variations and modifications may be considereddesirable by those skilled in the art based upon a review of theforegoing description of preferred embodiments. Accordingly, it isappropriate that the appended claims be construed broadly and in amanner consistent with the scope of the invention.

1. An apparatus for generating an oxygen-rich gas, comprising: acontainer for containing a chemical reaction producing at least in partan oxygen-rich gas, the chemical reaction occurring in the presence of aliquid; and a surfactant within the container for inhibiting formationof foam in the liquid resulting from the production of oxygen-rich gas.2. The apparatus of claim 1, wherein the container is portable.
 3. Theapparatus of claim 2, wherein the container is configured for use as amedical emergency oxygen source.
 4. A method of generating. anoxygen-rich gas, comprising: generating an oxygen-rich gas in one ormore quantities of a liquid at either or both a desired flow rate and adesired quantity; placing a surfactant in contact with at least one ofthe one or more quantities of liquid to inhibit formation of foam in theliquid resulting from at least the production of oxygen-rich gas.
 5. Themethod of claim 4, wherein the step of generating an oxygen-rich gasfurther comprises generating an oxygen-rich gas in at least twoinitially separate quantities of liquid.
 6. The method of claim 5,wherein the step of generating an oxygen-rich gas further comprisessimultaneously generating an oxygen-rich gas in each of the at least twoinitially separate quantities of liquid at a different rate.
 7. A methodof generating an oxygen-rich gas, comprising: generating an oxygen-richgas in one or more quantities of a liquid at either or both a desiredflow rate and a desired quantity, wherein the at least one powderreactant is dissolved in the one or more quantities of liquid togenerate the oxygen-rich gas and wherein the desired flow rate isachieved by varying one or more attributes of at least a portion of thepowder, comprising: applying one or more layers of a coating toparticles of the powder, selecting a desired thickness for the one ormore layers of coating and selecting a desired powder particle size; andplacing a surfactant in contact with at least one of the one or morequantities of liquid to inhibit formation of foam in the liquidresulting from at least the production of oxygen-rich gas.